Switch and Socket Endurance Tester

For industries that produce switches and socket and there would be a need to test the mechanical durability and electrical durability.

Dec 16, 2019

•

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6 respects

monitoring

Components and supplies

Alphanumeric LCD, 16 x 2

Push buttons (NO and NC)

Actuonix L12R/L16R linear servo

60W PCIe 12V 5A Power Supply

Solid State Relay, 12 A

Linear Regulator (7805)

DR-IAC5A

SD Card Module

Arduino UNO

ProtoScrewShield

Emergency Stop Switch, DPST

Tools and machines

Extraction Tool, 6 Piece Screw Extractor & Screwdriver Set

Wire Stripper & Cutter, 18-10 AWG / 0.75-4mm² Capacity Wires

Apps and platforms

Arduino IDE

Project description

Code

Switch/Socket Endurance Tester

c_cpp

1/*Project:Switch/Socket Endurance Tester
2  Author: Cajetan Chinonso  Emmanuel*/
3
4//#include <LEM.h>
5#include <Wire.h>                                                                   //  Include wire library
6#include <LiquidCrystal_I2C.h>                                                      //  Include New Liquid crystal for I2C bus
7#include <Servo.h>                                                                  //  Include Servo Library
8#include <SD.h>                                                                     //  Load SD library
9#include <SPI.h>                                                                    //  Load SPI library
10
11#define LINEAR_ACTUATORPIN1 5                                                       //  Define Servo Pin
12#define LINEAR_ACTUATORPIN2 6
13
14LiquidCrystal_I2C lcd(0x27,  20, 4);                                                 // set the LCD address to  0x27 for a 16 chars and 2 line display
15
16Servo LINEAR_ACTUATOR1;                                                             //  Set object as servo
17Servo LINEAR_ACTUATOR2;
18
19//int linearValue = 1000;                                                             // Value for linear  actuator on start
20
21int returnButton = 2;
22int startPin = 3;                                                                   //  Start pin
23int resetBoard = 9;
24int resetPin = 7;
25
26int count_A;                                                                          //  Counter 1 Value
27int count_B;
28
29const int setPoint = 10000;
30int countPin1  = A1;
31int countPin2 = A2;
32int startVal = 0;                                                                   //  Value to store start
33
34unsigned long currentMillis = 0;
35unsigned long currentMillis_B  = 0;
36unsigned long previousMillis;
37unsigned long previousMillis_B;
38
39const  long on_SetTime = 20000;
40
41byte currentButtonState_A;
42byte previousButtonState_A;
43
44byte  currentButtonState_B;
45byte previousButtonState_B;
46
47boolean counting;
48boolean  counting_B;
49
50//Lem sensor(HO_50_S, A0);
51
52const int chipSelect = 4;
53File  testData;
54
55
56void setup() {
57  Serial.begin(115200);                                                             //  Begin Serial Monitoring
58  //  sensor.calibrate();
59
60  digitalWrite(9, HIGH);
61
62  pinMode(9, OUTPUT);
63  SD.begin(chipSelect);
64
65  lcd.init();                                                                       //  LCD with 16 chars, 2 line display
66  lcd.clear();                                                                      //  Clear screen
67  lcd.backlight();
68  lcd.clear();
69  lcd.setCursor(0, 0);
70  lcd.print("Scanning...");
71
72  LINEAR_ACTUATOR1.attach(LINEAR_ACTUATORPIN1,  1000, 2000);                            // min and max position for servo
73  LINEAR_ACTUATOR1.writeMicroseconds(1550);
74  LINEAR_ACTUATOR2.attach(LINEAR_ACTUATORPIN2, 1000, 2000);
75  LINEAR_ACTUATOR2.writeMicroseconds(1550);
76
77
78  pinMode(startPin, INPUT_PULLUP);                                                   //  Set start pin as input
79  pinMode(resetPin, OUTPUT);
80  pinMode(A1, INPUT_PULLUP);
81  pinMode(A2, INPUT_PULLUP);
82  pinMode(2, INPUT_PULLUP);
83  pinMode(7, INPUT_PULLUP);
84
85  if (!SD.begin(chipSelect)) {
86    Serial.println("Card failed, or not present");
87    lcd.setCursor(0, 0);
88    lcd.print("No SD detected");
89    lcd.setCursor(0,  1);
90    lcd.print("Insert SD card");
91    delay(750);
92    digitalWrite(resetBoard,  LOW);
93    // don't do anything more:
94    while (1);
95  }
96  //  Serial.println("card  initialized.");
97  delay(200);
98  lcd.clear();
99}
100
101void stopRun() {
102  //  linearValue = 1075;
103  LINEAR_ACTUATOR1.writeMicroseconds(1000);
104  LINEAR_ACTUATOR2.writeMicroseconds(1000);
105}
106
107void  testFail() {
108  if (digitalRead(7) == HIGH) {
109    digitalWrite(resetBoard,  LOW);
110  }
111  lcd.clear();
112  lcd.setCursor(0, 0);
113  lcd.print("Failed  at " + String(count_A));
114  lcd.setCursor(0, 1);
115  lcd.print("Failed at "  + String(count_B));
116  delay(4000);
117}
118
119void loop() {
120  //  float I  = sensor.getCurrentAC();
121  startVal = digitalRead(startPin);
122
123  lcd.setCursor(3,  0);
124  lcd.print("INITIALISE");
125
126  if (digitalRead(2) == HIGH) {
127    stopRun();
128  }
129
130  if (digitalRead(7) == HIGH) {
131    digitalWrite(resetBoard, LOW);
132  }
133
134  if (startVal == LOW && digitalRead(2) == LOW) {
135
136    lcd.clear();
137    //    linearValue = 1000;
138    delay(1000);
139
140    while (startVal ==  LOW && digitalRead(2) == LOW) {
141
142      lcd.setCursor(0, 0);
143      lcd.print("Pos  1 =");
144      lcd.setCursor(0, 1);
145      lcd.print("Pos 2 =");
146
147      unsigned  long currentMillis = millis();
148      unsigned long currentMillis_B = millis();
149
150      previousButtonState_A = currentButtonState_A;
151      previousButtonState_B  = currentButtonState_B;
152
153      currentButtonState_A = digitalRead(A1);
154      currentButtonState_B = digitalRead(A2);
155
156      if (count_B <= 2 and  currentMillis_B - previousMillis_B >= 20000) {
157        if (counting_B = true)  {
158          lcd.setCursor(0, 1);
159          lcd.print("NOT APPLICABLE");
160          currentMillis_B = previousMillis_B;
161          counting_B = false;
162        }
163      }
164
165      if (currentButtonState_A == LOW) {
166        Serial.println("OFF");
167        //        linearValue = 1430;     //retract
168        //        delay(200);
169        //        currentMillis = onSwitch;
170        delay(200);
171        LINEAR_ACTUATOR1.writeMicroseconds(1550);
172        delay(200);
173        LINEAR_ACTUATOR2.writeMicroseconds(1800);
174        //        delay(200);
175      }
176
177      else {
178        if (previousButtonState_A  == HIGH) {
179          Serial.println("ON");
180          //          currentMillis  = offSwitch;
181          delay(200);
182          LINEAR_ACTUATOR1.writeMicroseconds(1800);
183          delay(200);
184          LINEAR_ACTUATOR2.writeMicroseconds(1550);
185          //          delay(200);
186        }
187      }
188
189      if (currentButtonState_A  == LOW and previousButtonState_A == HIGH) {
190
191        count_A++;
192        //        float I = sensor.getCurrentAC();
193
194        lcd.setCursor(8, 0);
195        lcd.print(count_A);
196        lcd.setCursor(0, 1);
197        //        lcd.print("Amp:  " + String(I) + "A");
198        //        Serial.println(count);
199        testData  = SD.open("TSTdata.txt", FILE_WRITE);
200        if (testData) {
201          testData.println("Number  of Cycles: " + String(count_A));
202          testData.println("");
203          testData.close();
204
205          /*Serial.println("Number of Cycles: " + String(count) + "; Current:  " + String(I * 11.538461538) + "A");
206            Serial.println("");*/
207        }
208
209        previousMillis = currentMillis;
210
211      }
212
213      else if (currentButtonState_B == LOW and previousButtonState_B == HIGH) {
214
215        count_B++;
216        //        float I = sensor.getCurrentAC();
217
218        lcd.setCursor(8, 1);
219        lcd.print(count_B);
220        lcd.setCursor(0,  1);
221        //        lcd.print("Amp: " + String(I) + "A");
222        //        Serial.println(count);
223        testData = SD.open("TSTdata.txt", FILE_WRITE);
224        if (testData) {
225          testData.println("Number of Cycles: " + String(count_B));
226          testData.println("");
227          testData.close();
228
229          /*Serial.println("Number  of Cycles: " + String(count) + "; Current: " + String(I * 11.538461538) + "A");
230            Serial.println("");*/
231        }
232
233        previousMillis =  currentMillis;
234
235      }
236
237
238      else if (count_A and count_B == setPoint)  {
239        while (counting = true) {
240          testData = SD.open("TSTdata.txt",  FILE_WRITE);
241          //          if (testData) {
242          //            testData.println("Cycles  completed; Current: " + String(I) + "A");
243          //            testData.println("");
244          //            testData.close();
245          //
246          //            /*Serial.println("Cycles  completed; Current: " + String(I * 11.538461538) + "A");
247          //              Serial.println("");*/
248          //          }
249
250
251          lcd.clear();
252          lcd.setCursor(0,  0);
253          lcd.print("Start New");
254          lcd.setCursor(0, 1);
255          lcd.print("Test Successful");
256          delay(4000);
257          counting  = false;
258
259          stopRun();
260          if (digitalRead(2) == HIGH) break;
261        }
262      }
263
264
265      else if ((currentButtonState_A == HIGH or  previousButtonState_A == LOW) && (currentMillis - previousMillis >= on_SetTime))  {
266        while (counting = true) {
267
268          testData = SD.open("TSTdata.txt",  FILE_WRITE);
269          previousMillis = currentMillis;
270          if (testData)  {
271            testData.println("Failed at " + String(count_A));
272            //            testData.println("Current at " + String(count_A) + ": ");
273            testData.println("");
274            testData.close();
275
276            /* Serial.println("Failed at "  + String(count));
277              Serial.println("Current at " + String(count)  + ": " + String(I * 11.538461538) + "A");
278              Serial.println("");*/
279          }
280          testFail();
281          delay(100);
282          stopRun();
283          counting = false;
284          if (digitalRead(2) == HIGH) break;
285        }
286      }
287
288      if (digitalRead(2) == HIGH) break;
289    }
290
291
292    if (digitalRead(2) == HIGH) {
293      lcd.clear();
294      lcd.setCursor(0,  0);
295      stopRun();
296    }
297  }
298}

/*Project:Switch/Socket Endurance Tester
  Author: Cajetan Chinonso  Emmanuel*/

//#include <LEM.h>
#include <Wire.h>                                                                   //  Include wire library
#include <LiquidCrystal_I2C.h>                                                      //  Include New Liquid crystal for I2C bus
#include <Servo.h>                                                                  //  Include Servo Library
#include <SD.h>                                                                     //  Load SD library
#include <SPI.h>                                                                    //  Load SPI library

#define LINEAR_ACTUATORPIN1 5                                                       //  Define Servo Pin
#define LINEAR_ACTUATORPIN2 6

LiquidCrystal_I2C lcd(0x27,  20, 4);                                                 // set the LCD address to  0x27 for a 16 chars and 2 line display

Servo LINEAR_ACTUATOR1;                                                             //  Set object as servo
Servo LINEAR_ACTUATOR2;

//int linearValue = 1000;                                                             // Value for linear  actuator on start

int returnButton = 2;
int startPin = 3;                                                                   //  Start pin
int resetBoard = 9;
int resetPin = 7;

int count_A;                                                                          //  Counter 1 Value
int count_B;

const int setPoint = 10000;
int countPin1  = A1;
int countPin2 = A2;
int startVal = 0;                                                                   //  Value to store start

unsigned long currentMillis = 0;
unsigned long currentMillis_B  = 0;
unsigned long previousMillis;
unsigned long previousMillis_B;

const  long on_SetTime = 20000;

byte currentButtonState_A;
byte previousButtonState_A;

byte  currentButtonState_B;
byte previousButtonState_B;

boolean counting;
boolean  counting_B;

//Lem sensor(HO_50_S, A0);

const int chipSelect = 4;
File  testData;


void setup() {
  Serial.begin(115200);                                                             //  Begin Serial Monitoring
  //  sensor.calibrate();

  digitalWrite(9, HIGH);

  pinMode(9, OUTPUT);
  SD.begin(chipSelect);

  lcd.init();                                                                       //  LCD with 16 chars, 2 line display
  lcd.clear();                                                                      //  Clear screen
  lcd.backlight();
  lcd.clear();
  lcd.setCursor(0, 0);
  lcd.print("Scanning...");

  LINEAR_ACTUATOR1.attach(LINEAR_ACTUATORPIN1,  1000, 2000);                            // min and max position for servo
  LINEAR_ACTUATOR1.writeMicroseconds(1550);
  LINEAR_ACTUATOR2.attach(LINEAR_ACTUATORPIN2, 1000, 2000);
  LINEAR_ACTUATOR2.writeMicroseconds(1550);


  pinMode(startPin, INPUT_PULLUP);                                                   //  Set start pin as input
  pinMode(resetPin, OUTPUT);
  pinMode(A1, INPUT_PULLUP);
  pinMode(A2, INPUT_PULLUP);
  pinMode(2, INPUT_PULLUP);
  pinMode(7, INPUT_PULLUP);

  if (!SD.begin(chipSelect)) {
    Serial.println("Card failed, or not present");
    lcd.setCursor(0, 0);
    lcd.print("No SD detected");
    lcd.setCursor(0,  1);
    lcd.print("Insert SD card");
    delay(750);
    digitalWrite(resetBoard,  LOW);
    // don't do anything more:
    while (1);
  }
  //  Serial.println("card  initialized.");
  delay(200);
  lcd.clear();
}

void stopRun() {
  //  linearValue = 1075;
  LINEAR_ACTUATOR1.writeMicroseconds(1000);
  LINEAR_ACTUATOR2.writeMicroseconds(1000);
}

void  testFail() {
  if (digitalRead(7) == HIGH) {
    digitalWrite(resetBoard,  LOW);
  }
  lcd.clear();
  lcd.setCursor(0, 0);
  lcd.print("Failed  at " + String(count_A));
  lcd.setCursor(0, 1);
  lcd.print("Failed at "  + String(count_B));
  delay(4000);
}

void loop() {
  //  float I  = sensor.getCurrentAC();
  startVal = digitalRead(startPin);

  lcd.setCursor(3,  0);
  lcd.print("INITIALISE");

  if (digitalRead(2) == HIGH) {
    stopRun();
  }

  if (digitalRead(7) == HIGH) {
    digitalWrite(resetBoard, LOW);
  }

  if (startVal == LOW && digitalRead(2) == LOW) {

    lcd.clear();
    //    linearValue = 1000;
    delay(1000);

    while (startVal ==  LOW && digitalRead(2) == LOW) {

      lcd.setCursor(0, 0);
      lcd.print("Pos  1 =");
      lcd.setCursor(0, 1);
      lcd.print("Pos 2 =");

      unsigned  long currentMillis = millis();
      unsigned long currentMillis_B = millis();

      previousButtonState_A = currentButtonState_A;
      previousButtonState_B  = currentButtonState_B;

      currentButtonState_A = digitalRead(A1);
      currentButtonState_B = digitalRead(A2);

      if (count_B <= 2 and  currentMillis_B - previousMillis_B >= 20000) {
        if (counting_B = true)  {
          lcd.setCursor(0, 1);
          lcd.print("NOT APPLICABLE");
          currentMillis_B = previousMillis_B;
          counting_B = false;
        }
      }

      if (currentButtonState_A == LOW) {
        Serial.println("OFF");
        //        linearValue = 1430;     //retract
        //        delay(200);
        //        currentMillis = onSwitch;
        delay(200);
        LINEAR_ACTUATOR1.writeMicroseconds(1550);
        delay(200);
        LINEAR_ACTUATOR2.writeMicroseconds(1800);
        //        delay(200);
      }

      else {
        if (previousButtonState_A  == HIGH) {
          Serial.println("ON");
          //          currentMillis  = offSwitch;
          delay(200);
          LINEAR_ACTUATOR1.writeMicroseconds(1800);
          delay(200);
          LINEAR_ACTUATOR2.writeMicroseconds(1550);
          //          delay(200);
        }
      }

      if (currentButtonState_A  == LOW and previousButtonState_A == HIGH) {

        count_A++;
        //        float I = sensor.getCurrentAC();

        lcd.setCursor(8, 0);
        lcd.print(count_A);
        lcd.setCursor(0, 1);
        //        lcd.print("Amp:  " + String(I) + "A");
        //        Serial.println(count);
        testData  = SD.open("TSTdata.txt", FILE_WRITE);
        if (testData) {
          testData.println("Number  of Cycles: " + String(count_A));
          testData.println("");
          testData.close();

          /*Serial.println("Number of Cycles: " + String(count) + "; Current:  " + String(I * 11.538461538) + "A");
            Serial.println("");*/
        }

        previousMillis = currentMillis;

      }

      else if (currentButtonState_B == LOW and previousButtonState_B == HIGH) {

        count_B++;
        //        float I = sensor.getCurrentAC();

        lcd.setCursor(8, 1);
        lcd.print(count_B);
        lcd.setCursor(0,  1);
        //        lcd.print("Amp: " + String(I) + "A");
        //        Serial.println(count);
        testData = SD.open("TSTdata.txt", FILE_WRITE);
        if (testData) {
          testData.println("Number of Cycles: " + String(count_B));
          testData.println("");
          testData.close();

          /*Serial.println("Number  of Cycles: " + String(count) + "; Current: " + String(I * 11.538461538) + "A");
            Serial.println("");*/
        }

        previousMillis =  currentMillis;

      }


      else if (count_A and count_B == setPoint)  {
        while (counting = true) {
          testData = SD.open("TSTdata.txt",  FILE_WRITE);
          //          if (testData) {
          //            testData.println("Cycles  completed; Current: " + String(I) + "A");
          //            testData.println("");
          //            testData.close();
          //
          //            /*Serial.println("Cycles  completed; Current: " + String(I * 11.538461538) + "A");
          //              Serial.println("");*/
          //          }


          lcd.clear();
          lcd.setCursor(0,  0);
          lcd.print("Start New");
          lcd.setCursor(0, 1);
          lcd.print("Test Successful");
          delay(4000);
          counting  = false;

          stopRun();
          if (digitalRead(2) == HIGH) break;
        }
      }


      else if ((currentButtonState_A == HIGH or  previousButtonState_A == LOW) && (currentMillis - previousMillis >= on_SetTime))  {
        while (counting = true) {

          testData = SD.open("TSTdata.txt",  FILE_WRITE);
          previousMillis = currentMillis;
          if (testData)  {
            testData.println("Failed at " + String(count_A));
            //            testData.println("Current at " + String(count_A) + ": ");
            testData.println("");
            testData.close();

            /* Serial.println("Failed at "  + String(count));
              Serial.println("Current at " + String(count)  + ": " + String(I * 11.538461538) + "A");
              Serial.println("");*/
          }
          testFail();
          delay(100);
          stopRun();
          counting = false;
          if (digitalRead(2) == HIGH) break;
        }
      }

      if (digitalRead(2) == HIGH) break;
    }


    if (digitalRead(2) == HIGH) {
      lcd.clear();
      lcd.setCursor(0,  0);
      stopRun();
    }
  }
}

Switch/Socket Endurance Tester

c_cpp

1/*Project:Switch/Socket Endurance Tester
2  Author: Cajetan Chinonso
3  Emmanuel*/
4
5//#include <LEM.h>
6#include <Wire.h>                                                                   //
7  Include wire library
8#include <LiquidCrystal_I2C.h>                                                      //
9  Include New Liquid crystal for I2C bus
10#include <Servo.h>                                                                  //
11  Include Servo Library
12#include <SD.h>                                                                     //
13  Load SD library
14#include <SPI.h>                                                                    //
15  Load SPI library
16
17#define LINEAR_ACTUATORPIN1 5                                                       //
18  Define Servo Pin
19#define LINEAR_ACTUATORPIN2 6
20
21LiquidCrystal_I2C lcd(0x27,
22  20, 4);                                                 // set the LCD address to
23  0x27 for a 16 chars and 2 line display
24
25Servo LINEAR_ACTUATOR1;                                                             //
26  Set object as servo
27Servo LINEAR_ACTUATOR2;
28
29//int linearValue = 1000;
30                                                             // Value for linear
31  actuator on start
32
33int returnButton = 2;
34int startPin = 3;                                                                   //
35  Start pin
36int resetBoard = 9;
37int resetPin = 7;
38
39int count_A;                                                                          //
40  Counter 1 Value
41int count_B;
42
43const int setPoint = 10000;
44int countPin1
45  = A1;
46int countPin2 = A2;
47int startVal = 0;                                                                   //
48  Value to store start
49
50unsigned long currentMillis = 0;
51unsigned long currentMillis_B
52  = 0;
53unsigned long previousMillis;
54unsigned long previousMillis_B;
55
56const
57  long on_SetTime = 20000;
58
59byte currentButtonState_A;
60byte previousButtonState_A;
61
62byte
63  currentButtonState_B;
64byte previousButtonState_B;
65
66boolean counting;
67boolean
68  counting_B;
69
70//Lem sensor(HO_50_S, A0);
71
72const int chipSelect = 4;
73File
74  testData;
75
76
77void setup() {
78  Serial.begin(115200);                                                             //
79  Begin Serial Monitoring
80  //  sensor.calibrate();
81
82  digitalWrite(9, HIGH);
83
84
85  pinMode(9, OUTPUT);
86  SD.begin(chipSelect);
87
88  lcd.init();                                                                       //
89  LCD with 16 chars, 2 line display
90  lcd.clear();                                                                      //
91  Clear screen
92  lcd.backlight();
93  lcd.clear();
94  lcd.setCursor(0, 0);
95
96  lcd.print("Scanning...");
97
98  LINEAR_ACTUATOR1.attach(LINEAR_ACTUATORPIN1,
99  1000, 2000);                            // min and max position for servo
100  LINEAR_ACTUATOR1.writeMicroseconds(1550);
101
102  LINEAR_ACTUATOR2.attach(LINEAR_ACTUATORPIN2, 1000, 2000);
103  LINEAR_ACTUATOR2.writeMicroseconds(1550);
104
105
106
107  pinMode(startPin, INPUT_PULLUP);                                                   //
108  Set start pin as input
109  pinMode(resetPin, OUTPUT);
110  pinMode(A1, INPUT_PULLUP);
111
112  pinMode(A2, INPUT_PULLUP);
113  pinMode(2, INPUT_PULLUP);
114  pinMode(7, INPUT_PULLUP);
115
116
117  if (!SD.begin(chipSelect)) {
118    Serial.println("Card failed, or not present");
119
120    lcd.setCursor(0, 0);
121    lcd.print("No SD detected");
122    lcd.setCursor(0,
123  1);
124    lcd.print("Insert SD card");
125    delay(750);
126    digitalWrite(resetBoard,
127  LOW);
128    // don't do anything more:
129    while (1);
130  }
131  //  Serial.println("card
132  initialized.");
133  delay(200);
134  lcd.clear();
135}
136
137void stopRun() {
138
139  //  linearValue = 1075;
140  LINEAR_ACTUATOR1.writeMicroseconds(1000);
141  LINEAR_ACTUATOR2.writeMicroseconds(1000);
142}
143
144void
145  testFail() {
146  if (digitalRead(7) == HIGH) {
147    digitalWrite(resetBoard,
148  LOW);
149  }
150  lcd.clear();
151  lcd.setCursor(0, 0);
152  lcd.print("Failed
153  at " + String(count_A));
154  lcd.setCursor(0, 1);
155  lcd.print("Failed at "
156  + String(count_B));
157  delay(4000);
158}
159
160void loop() {
161  //  float I
162  = sensor.getCurrentAC();
163  startVal = digitalRead(startPin);
164
165  lcd.setCursor(3,
166  0);
167  lcd.print("INITIALISE");
168
169  if (digitalRead(2) == HIGH) {
170    stopRun();
171
172  }
173
174  if (digitalRead(7) == HIGH) {
175    digitalWrite(resetBoard, LOW);
176
177  }
178
179  if (startVal == LOW && digitalRead(2) == LOW) {
180
181    lcd.clear();
182
183    //    linearValue = 1000;
184    delay(1000);
185
186    while (startVal ==
187  LOW && digitalRead(2) == LOW) {
188
189      lcd.setCursor(0, 0);
190      lcd.print("Pos
191  1 =");
192      lcd.setCursor(0, 1);
193      lcd.print("Pos 2 =");
194
195      unsigned
196  long currentMillis = millis();
197      unsigned long currentMillis_B = millis();
198
199
200      previousButtonState_A = currentButtonState_A;
201      previousButtonState_B
202  = currentButtonState_B;
203
204      currentButtonState_A = digitalRead(A1);
205
206      currentButtonState_B = digitalRead(A2);
207
208      if (count_B <= 2 and
209  currentMillis_B - previousMillis_B >= 20000) {
210        if (counting_B = true)
211  {
212          lcd.setCursor(0, 1);
213          lcd.print("NOT APPLICABLE");
214
215          currentMillis_B = previousMillis_B;
216          counting_B = false;
217
218        }
219      }
220
221      if (currentButtonState_A == LOW) {
222        Serial.println("OFF");
223
224        //        linearValue = 1430;     //retract
225        //        delay(200);
226
227        //        currentMillis = onSwitch;
228        delay(200);
229        LINEAR_ACTUATOR1.writeMicroseconds(1550);
230
231        delay(200);
232        LINEAR_ACTUATOR2.writeMicroseconds(1800);
233        //
234        delay(200);
235      }
236
237      else {
238        if (previousButtonState_A
239  == HIGH) {
240          Serial.println("ON");
241          //          currentMillis
242  = offSwitch;
243          delay(200);
244          LINEAR_ACTUATOR1.writeMicroseconds(1800);
245
246          delay(200);
247          LINEAR_ACTUATOR2.writeMicroseconds(1550);
248
249          //          delay(200);
250        }
251      }
252
253      if (currentButtonState_A
254  == LOW and previousButtonState_A == HIGH) {
255
256        count_A++;
257        //
258        float I = sensor.getCurrentAC();
259
260        lcd.setCursor(8, 0);
261
262        lcd.print(count_A);
263        lcd.setCursor(0, 1);
264        //        lcd.print("Amp:
265  " + String(I) + "A");
266        //        Serial.println(count);
267        testData
268  = SD.open("TSTdata.txt", FILE_WRITE);
269        if (testData) {
270          testData.println("Number
271  of Cycles: " + String(count_A));
272          testData.println("");
273          testData.close();
274
275
276          /*Serial.println("Number of Cycles: " + String(count) + "; Current:
277  " + String(I * 11.538461538) + "A");
278            Serial.println("");*/
279
280        }
281
282        previousMillis = currentMillis;
283
284      }
285
286
287      else if (currentButtonState_B == LOW and previousButtonState_B == HIGH) {
288
289
290        count_B++;
291        //        float I = sensor.getCurrentAC();
292
293
294        lcd.setCursor(8, 1);
295        lcd.print(count_B);
296        lcd.setCursor(0,
297  1);
298        //        lcd.print("Amp: " + String(I) + "A");
299        //
300        Serial.println(count);
301        testData = SD.open("TSTdata.txt", FILE_WRITE);
302
303        if (testData) {
304          testData.println("Number of Cycles: " + String(count_B));
305
306          testData.println("");
307          testData.close();
308
309          /*Serial.println("Number
310  of Cycles: " + String(count) + "; Current: " + String(I * 11.538461538) + "A");
311
312            Serial.println("");*/
313        }
314
315        previousMillis =
316  currentMillis;
317
318      }
319
320
321      else if (count_A and count_B == setPoint)
322  {
323        while (counting = true) {
324          testData = SD.open("TSTdata.txt",
325  FILE_WRITE);
326          //          if (testData) {
327          //            testData.println("Cycles
328  completed; Current: " + String(I) + "A");
329          //            testData.println("");
330
331          //            testData.close();
332          //
333          //            /*Serial.println("Cycles
334  completed; Current: " + String(I * 11.538461538) + "A");
335          //              Serial.println("");*/
336
337          //          }
338
339
340          lcd.clear();
341          lcd.setCursor(0,
342  0);
343          lcd.print("Start New");
344          lcd.setCursor(0, 1);
345
346          lcd.print("Test Successful");
347          delay(4000);
348          counting
349  = false;
350
351          stopRun();
352          if (digitalRead(2) == HIGH) break;
353
354        }
355      }
356
357
358      else if ((currentButtonState_A == HIGH or
359  previousButtonState_A == LOW) && (currentMillis - previousMillis >= on_SetTime))
360  {
361        while (counting = true) {
362
363          testData = SD.open("TSTdata.txt",
364  FILE_WRITE);
365          previousMillis = currentMillis;
366          if (testData)
367  {
368            testData.println("Failed at " + String(count_A));
369            //
370            testData.println("Current at " + String(count_A) + ": ");
371            testData.println("");
372
373            testData.close();
374
375            /* Serial.println("Failed at "
376  + String(count));
377              Serial.println("Current at " + String(count)
378  + ": " + String(I * 11.538461538) + "A");
379              Serial.println("");*/
380
381          }
382          testFail();
383          delay(100);
384          stopRun();
385
386          counting = false;
387          if (digitalRead(2) == HIGH) break;
388
389        }
390      }
391
392      if (digitalRead(2) == HIGH) break;
393    }
394
395
396
397    if (digitalRead(2) == HIGH) {
398      lcd.clear();
399      lcd.setCursor(0,
400  0);
401      stopRun();
402    }
403  }
404}

/*Project:Switch/Socket Endurance Tester
  Author: Cajetan Chinonso
  Emmanuel*/

//#include <LEM.h>
#include <Wire.h>                                                                   //
  Include wire library
#include <LiquidCrystal_I2C.h>                                                      //
  Include New Liquid crystal for I2C bus
#include <Servo.h>                                                                  //
  Include Servo Library
#include <SD.h>                                                                     //
  Load SD library
#include <SPI.h>                                                                    //
  Load SPI library

#define LINEAR_ACTUATORPIN1 5                                                       //
  Define Servo Pin
#define LINEAR_ACTUATORPIN2 6

LiquidCrystal_I2C lcd(0x27,
  20, 4);                                                 // set the LCD address to
  0x27 for a 16 chars and 2 line display

Servo LINEAR_ACTUATOR1;                                                             //
  Set object as servo
Servo LINEAR_ACTUATOR2;

//int linearValue = 1000;
                                                             // Value for linear
  actuator on start

int returnButton = 2;
int startPin = 3;                                                                   //
  Start pin
int resetBoard = 9;
int resetPin = 7;

int count_A;                                                                          //
  Counter 1 Value
int count_B;

const int setPoint = 10000;
int countPin1
  = A1;
int countPin2 = A2;
int startVal = 0;                                                                   //
  Value to store start

unsigned long currentMillis = 0;
unsigned long currentMillis_B
  = 0;
unsigned long previousMillis;
unsigned long previousMillis_B;

const
  long on_SetTime = 20000;

byte currentButtonState_A;
byte previousButtonState_A;

byte
  currentButtonState_B;
byte previousButtonState_B;

boolean counting;
boolean
  counting_B;

//Lem sensor(HO_50_S, A0);

const int chipSelect = 4;
File
  testData;


void setup() {
  Serial.begin(115200);                                                             //
  Begin Serial Monitoring
  //  sensor.calibrate();

  digitalWrite(9, HIGH);


  pinMode(9, OUTPUT);
  SD.begin(chipSelect);

  lcd.init();                                                                       //
  LCD with 16 chars, 2 line display
  lcd.clear();                                                                      //
  Clear screen
  lcd.backlight();
  lcd.clear();
  lcd.setCursor(0, 0);

  lcd.print("Scanning...");

  LINEAR_ACTUATOR1.attach(LINEAR_ACTUATORPIN1,
  1000, 2000);                            // min and max position for servo
  LINEAR_ACTUATOR1.writeMicroseconds(1550);

  LINEAR_ACTUATOR2.attach(LINEAR_ACTUATORPIN2, 1000, 2000);
  LINEAR_ACTUATOR2.writeMicroseconds(1550);



  pinMode(startPin, INPUT_PULLUP);                                                   //
  Set start pin as input
  pinMode(resetPin, OUTPUT);
  pinMode(A1, INPUT_PULLUP);

  pinMode(A2, INPUT_PULLUP);
  pinMode(2, INPUT_PULLUP);
  pinMode(7, INPUT_PULLUP);


  if (!SD.begin(chipSelect)) {
    Serial.println("Card failed, or not present");

    lcd.setCursor(0, 0);
    lcd.print("No SD detected");
    lcd.setCursor(0,
  1);
    lcd.print("Insert SD card");
    delay(750);
    digitalWrite(resetBoard,
  LOW);
    // don't do anything more:
    while (1);
  }
  //  Serial.println("card
  initialized.");
  delay(200);
  lcd.clear();
}

void stopRun() {

  //  linearValue = 1075;
  LINEAR_ACTUATOR1.writeMicroseconds(1000);
  LINEAR_ACTUATOR2.writeMicroseconds(1000);
}

void
  testFail() {
  if (digitalRead(7) == HIGH) {
    digitalWrite(resetBoard,
  LOW);
  }
  lcd.clear();
  lcd.setCursor(0, 0);
  lcd.print("Failed
  at " + String(count_A));
  lcd.setCursor(0, 1);
  lcd.print("Failed at "
  + String(count_B));
  delay(4000);
}

void loop() {
  //  float I
  = sensor.getCurrentAC();
  startVal = digitalRead(startPin);

  lcd.setCursor(3,
  0);
  lcd.print("INITIALISE");

  if (digitalRead(2) == HIGH) {
    stopRun();

  }

  if (digitalRead(7) == HIGH) {
    digitalWrite(resetBoard, LOW);

  }

  if (startVal == LOW && digitalRead(2) == LOW) {

    lcd.clear();

    //    linearValue = 1000;
    delay(1000);

    while (startVal ==
  LOW && digitalRead(2) == LOW) {

      lcd.setCursor(0, 0);
      lcd.print("Pos
  1 =");
      lcd.setCursor(0, 1);
      lcd.print("Pos 2 =");

      unsigned
  long currentMillis = millis();
      unsigned long currentMillis_B = millis();


      previousButtonState_A = currentButtonState_A;
      previousButtonState_B
  = currentButtonState_B;

      currentButtonState_A = digitalRead(A1);

      currentButtonState_B = digitalRead(A2);

      if (count_B <= 2 and
  currentMillis_B - previousMillis_B >= 20000) {
        if (counting_B = true)
  {
          lcd.setCursor(0, 1);
          lcd.print("NOT APPLICABLE");

          currentMillis_B = previousMillis_B;
          counting_B = false;

        }
      }

      if (currentButtonState_A == LOW) {
        Serial.println("OFF");

        //        linearValue = 1430;     //retract
        //        delay(200);

        //        currentMillis = onSwitch;
        delay(200);
        LINEAR_ACTUATOR1.writeMicroseconds(1550);

        delay(200);
        LINEAR_ACTUATOR2.writeMicroseconds(1800);
        //
        delay(200);
      }

      else {
        if (previousButtonState_A
  == HIGH) {
          Serial.println("ON");
          //          currentMillis
  = offSwitch;
          delay(200);
          LINEAR_ACTUATOR1.writeMicroseconds(1800);

          delay(200);
          LINEAR_ACTUATOR2.writeMicroseconds(1550);

          //          delay(200);
        }
      }

      if (currentButtonState_A
  == LOW and previousButtonState_A == HIGH) {

        count_A++;
        //
        float I = sensor.getCurrentAC();

        lcd.setCursor(8, 0);

        lcd.print(count_A);
        lcd.setCursor(0, 1);
        //        lcd.print("Amp:
  " + String(I) + "A");
        //        Serial.println(count);
        testData
  = SD.open("TSTdata.txt", FILE_WRITE);
        if (testData) {
          testData.println("Number
  of Cycles: " + String(count_A));
          testData.println("");
          testData.close();


          /*Serial.println("Number of Cycles: " + String(count) + "; Current:
  " + String(I * 11.538461538) + "A");
            Serial.println("");*/

        }

        previousMillis = currentMillis;

      }


      else if (currentButtonState_B == LOW and previousButtonState_B == HIGH) {


        count_B++;
        //        float I = sensor.getCurrentAC();


        lcd.setCursor(8, 1);
        lcd.print(count_B);
        lcd.setCursor(0,
  1);
        //        lcd.print("Amp: " + String(I) + "A");
        //
        Serial.println(count);
        testData = SD.open("TSTdata.txt", FILE_WRITE);

        if (testData) {
          testData.println("Number of Cycles: " + String(count_B));

          testData.println("");
          testData.close();

          /*Serial.println("Number
  of Cycles: " + String(count) + "; Current: " + String(I * 11.538461538) + "A");

            Serial.println("");*/
        }

        previousMillis =
  currentMillis;

      }


      else if (count_A and count_B == setPoint)
  {
        while (counting = true) {
          testData = SD.open("TSTdata.txt",
  FILE_WRITE);
          //          if (testData) {
          //            testData.println("Cycles
  completed; Current: " + String(I) + "A");
          //            testData.println("");

          //            testData.close();
          //
          //            /*Serial.println("Cycles
  completed; Current: " + String(I * 11.538461538) + "A");
          //              Serial.println("");*/

          //          }


          lcd.clear();
          lcd.setCursor(0,
  0);
          lcd.print("Start New");
          lcd.setCursor(0, 1);

          lcd.print("Test Successful");
          delay(4000);
          counting
  = false;

          stopRun();
          if (digitalRead(2) == HIGH) break;

        }
      }


      else if ((currentButtonState_A == HIGH or
  previousButtonState_A == LOW) && (currentMillis - previousMillis >= on_SetTime))
  {
        while (counting = true) {

          testData = SD.open("TSTdata.txt",
  FILE_WRITE);
          previousMillis = currentMillis;
          if (testData)
  {
            testData.println("Failed at " + String(count_A));
            //
            testData.println("Current at " + String(count_A) + ": ");
            testData.println("");

            testData.close();

            /* Serial.println("Failed at "
  + String(count));
              Serial.println("Current at " + String(count)
  + ": " + String(I * 11.538461538) + "A");
              Serial.println("");*/

          }
          testFail();
          delay(100);
          stopRun();

          counting = false;
          if (digitalRead(2) == HIGH) break;

        }
      }

      if (digitalRead(2) == HIGH) break;
    }



    if (digitalRead(2) == HIGH) {
      lcd.clear();
      lcd.setCursor(0,
  0);
      stopRun();
    }
  }
}

Downloadable files

Switch and socket tester schematics

switch and socket tester schematics

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